DESIGN, FABRICATION AND PERFORMANCE

EVALUATION OF A COFFEE BEAN (Coffea sp.)

ROASTER
Donna Grace Marie O. Postrano, Ben-Hur C. Rafosala, Sheila C. Cogay, Ireneo P. Amplayo
University of Southeastern Philippines Tagum-Mabini Campus

Abstract This study was conducted to design, construct, and evaluate the performance of a coffee bean roaster. This machine would
help the small scale coffee growers to reduce time and effort of roasting their own product or selling their unroasted coffee beans
directly in a lower price. The performance of coffee beans when roasted was evaluated in terms of capacity, efficiency, and quality in
roasting based on its aroma, color, and taste. The study focused only on one factor which was the rpm of the machine. Every treatment
was replicated three (3) times and 1kg of coffee beans was used in every replication. The treatments applied to this study were the
22rpm, the 32rpm and the 42rpm. Among these treatments the 42rpm significantly increased the roasting rate having an average of
82.70000 while the 22rpm and 32rpm both yields insignificant effect with a mean value of 61.96667 and 70.7333, respectively. A taste
evaluation through a committee of 5 people were conducted to identify the effect of the treatment applied to the coffee beans. The
22rpm significantly had the highest average score with 3.5, while the 32rpm and the 42rpm have average score of 3.05 and 2.6
respectively. Cost estimate for the machine was also performed resulting to BCR of 1.40 which means that the designed machine is
economically feasible.

Index Terms-Coffee Beans,Coffee Roaster, Roasting, Quality of Roasting

1 INTRODUCTION
C offee is a beanlike seed of tropical evergreen
shrub of the genus Coffea, in the Madder family
(Rubiaceae), which has opposite leaves, cream-colored
flowers, and berry-like fruit. It is the second important
product in the international commerce based on the volume
Ctraded and it is estimated to be the first based on value; are
used in flavors and extracts (Pizon, 2003).
There are 25 major species of coffee but there are
only two that are likely to be familiar, Coffea arabica and the
Coffea anaphora producing robusta beans (Encyclopedia
Americana, 1998).
In dry techniques, the coffee fruits are set in the
sun on enormous yards for about fourteen days or more and
raked a few times each day to encourage notwithstanding
drying (Pizon, 2003).
A good quality cup of coffee is reliant on many
factors, such as the quality of green beans, the roasting
conditions, the time since the beans are roasted, and the
type of water used for brewing. More than 800 volatile
compounds have been identified in roasted coffee, whereof
around 30 compounds are responsible for the main
impression of coffee aroma (Baggenstoss et al. 2008).
The value of coffee is estimated to reach two
billion dollars a year or 1% of the total world trade. Among
major agricultural products of the world, coffee is unusual
because its cultivation, harvesting and much of processing
remain largely untouched by mechanization (Compton’s
Encyclopedia, 1986).
Today, coffee is known worldwide and has ranked
second to oil in terms of global demand. About 25 million
people worldwide, mostly small farmers, depend on coffee
farming for livelihood. One hundred forty-five million bags
(@60 kg/bag) of coffee were produced by exporting
countries valued at the US $ 21 billion. Around 34% of the
total production came from Brazil, followed by Vietnam and
Indonesia, with 18% and 8% contributions, respectively.
The Philippine coffee production accounted for less than
one percent (1%) livelihood (International Coffee
Organization (ICO), 2013).
The country has 119,999 hectares of land devoted
to coffee with an estimated 83.5 million fruit-bearing trees.
The bulk of production is in Mindanao with 64% of the total
land area and 69% of the total number of fruit-bearing trees,
respectively. SOCCKSARGEN has the largest coffee farm
area with 25,223 hectares, followed by the Davao Region
with 25,166 hectares, ARMM with 13,746 hectares,
CALABARZON with 13,563 hectares, and Northern
Mindanao with 11,837 hectares (Bureau of Agricultural
Statistics, 2012).
Despite its potential, coffee does not contribute
much to the gross value of agriculture in the country. From
2011 to 2013, the gross value of coffee output was valued at
PHP 5.8 million annually, on average. A decreasing rate on
the gross value of coffee was recorded from 2011-2013.
Moreover, from the 1.2% contribution of the agriculture and
forestry sector to the country's Gross Domestic Product
(GDP) in 2013, coffee contributed a mere 0.5% to total gross
value (National Statistical Coordination Board (NSCB),
2013).
Coffee processing today had been enhanced by
technologies through mechanical roasters in roasting to
reduce operational cost and labor. The coffee roaster
minimizes the damage to beans and is proven to be a better
method with faster and greater outputs.
Roasting brings out the aroma and flavor that is
locked inside the green coffee beans. It causes chemical
changes to take place as the beans are rapidly brought to
very high temperatures (NCA National Coffee Association).
 DGM.O Postrano, BS Agricultural Engineering Student, University of more efficient and effective for roasting coffee beans. This
Southeastern Philippines, Tagum City, Philippines machine would help the small-scale coffee growers to
Email: postranodonnagracemarie@gmail.com
reduce the time and effort of roasting their product or selling
 B.C. Rafosala, Chancellor, University of Southeastern Philippines, Tagum City,
Philippines
their unroasted coffee beans directly at a lower price.
Email: benhur.rafosala@usep.edu.ph Moreover, this study also serves as a reference for
 S.C. Cogay, Department Head, Department of Agricultural Engineering, further enhancement of the process of roasting coffee beans
University of Southeastern Philippines, Tagum City, Philippines that would help small-scale farmers to construct a
Email: sheila.cogay@usep.edu.ph mechanical roaster, which is locally fabricated; not only for
 I.P. Amplayo, Professor VI, Department of Agricultural Engineering, University
coffee but also for other bean crops to increase their income
of Southeastern Philippines, Tagum City, Philippines
and quality.
Using the coffee roaster, this research aims to yield a
satisfactory roasting quality of coffee beans based on its
appearance after the process. Thus, this study dug into
fabricating a mechanized coffee bean roaster to make it

2 METHODOLOGY
2.1 Description of the Design
Procedural Framework
Figure 1. Procedural Framework
Quantity Item
1 Stainless steel plate
1 V-Belt Pulley
1 G. I Sheet
1 V-Belt Pulley
1 Stainless Shafting
1 V-Belt Pulley
1 Electric motor
2 Angle Bar
1 Gear reducer
1 V-Belt Pulley
1 V-Belt Pulley
Pillow Block
1 type #206
Bearing lock type
1 V-Belt Pulley
Bolts w/ nuts and
6 2.5 Data Gathering
washers
2.2 Computation for Drumspeed
30
x√
g
=
π r
30
= x 6.948205456
π
= 66.35 rpm - 25 = 41 rpm
2.3 Operating Procedure
The steps and procedures for the operation and data
gathering on coffee bean roaster are the following:
1. 1kg of Coffee bean (dried) to be roasted are native.
2. Measure the beans to get the initial weight. 9
kilograms were weighed using a weighing scale.
These served as a medium for the research study;
3. To start the operation, the engine was set to its
assumed rpm by using a tachometer and must
preheat the roaster at the desired temperature.
4. For the first replication, 1 kilogram of coffee beans
were loaded to the roaster.
5. After the roasting process, the capacity, efficiency,
and quality must be evaluated.
6. Operations were repeated three times in every
treatment in the same manner to minimize the
error of closure and to determine the average
capacity, efficiency, and performance of the
prototype. If all the operations are done, the
cleaning of the machine must be made to make it
Size
ready and available for the next operation or run.
1.2mmx4’x8’
Then it was stored it in a secure area.
2” diameter
1.2mm x4'x8'
3" diameter
1" diameter x 24"
4" diameter
1/4 hp
1/8x1”x1”x20’
(Ratio 1:40)
5” diameter
B66
B58 Figure 2. Perspective view of the machine.
1/2 x 1 ½ and
3/8x 1 ½
There was data gathering before, during and after
the operation. For every operation, three replications were
m
done for each trial to get an accurate result. At the start of
9.81
30
x√ s2 data gathering, the fabricated machine was checked to
π 0.2032 ensure its full function and performance in the operation. It
was then followed by putting the fixed weight of the coffee
beans into the container, then starting and setting the rice
hull stove to start the machine roasting process. As soon as
the operation started, time was set until the process was
done. After that, everything was set off and then removed Roasting Efficiency of the machine
the output coffee beans and placed it into a sealed container.
When the first trial ended, the process was repeated until The roasted beans were weighed and the roasting
all the operations for each trial were done. efficiency was calculated as follows:
RB
RE= t x 100 (Eqn. 1)
2.6 Preparation and Performance Evaluation WBt

Testing Where:
The fabricated design was tested to determine the RE = Roasting efficiency
efficiency of the machine to roast and to know the ratio of RBt = total weight of roasted beans, kg
the weights of the beans partially and totally roasted to the WBt = total weight of coffee berries before loading
weight of the input coffee beans. Following the proper
procedures, 1 kg of coffee beans were loaded and had been Sensory Evaluation
roasted for 30 minutes. As a result of the first trial, the Sensory evaluation was done to evaluate the
output product appearance was bad and could not satisfy a changes of the roasted coffee beans as an effect of the given
consumer in the market. Since the result was not as good as treatment. This was done with Likert's scale under the
expected, the researcher decided to extend the roasting time expertise type of evaluation wherein only five (5) people
to 40 minutes for the second trial and repeated the with the necessary taste traits were selected to act as
operation. The result was noticeably a lot better than the respondents.
first trial and has a higher marketability potential.
Table 2. Mean scale and the descriptive interpretation of
the questionnaire.
Scale Descriptive Qualitative
Interpretation Description
In (%)
4.20 – This means that the 81 -100
5.00 quality of roasted
sampler is too high
FIRST TRIAL SECOND TRIAL 3.40 – This means that the 61-80
Figure 3. Preliminary Roasted beans 4.19 quality of the roasted
sample is high
2.60 – This means that the 41-60
Methods of Determining Roasting Efficiency
3.39 quality of the roasted
The primary consideration for determining the
sample is moderate.
roasting efficiency in percent was by weight basis. The
1.80 - This means that the 21-40
weight of roasted coffee bean and weight of unroasted coffee
2.59 quality of the roasted
bean loaded together were measured in kilograms on a
sample is low.
weighing scale. The total weight of roasted beans is divided
1 – 1.79 This means that the 1-20
by the total weight of coffee berries before loading
quality of the roasted
multiplied by 100.
sample is very low.
Experimental Design
The experiment was conducted in Complete
2.7 Economic Evaluation of Coffee Bean Roaster
Randomized Design (CRD) with three (3) treatments and
three (3) replications. Each sample unit has a weight of 1kg The economic analysis of the coffee bean roaster
(kilogram). The study used factors namely: rpm (T1, T2, and will be performed in terms of the Benefit-Cost Ratio (BCR).
T3) and roasting performance as shown in Table 1. The parameters that must be considered are depreciation as
computed using the Straight Line Formula Method. The
Statistical Tool initial cost which includes the cost materials and labor of
Analysis of Variance was used as a statistical tool construction, the savage value that is normally 10% of the
to test the significant difference among treatments and the initial cost of the coffee bean roaster and the assumed 5 years
significant effect of the independent variables on the life span of the storage.
dependent variables. The Tukey’s Studentized Range Test
was applied in the study to compare the significant effect (𝐼𝐶 − 𝑆𝑉)
among the treatments. 𝐷=
𝐿𝑆
Where:
Table 1. Treatment and Performance Parameters D= Depreciation Cost of the machine
Replications IC= Investment Cost
RPM SV= Salvage Value (10% of the Initial Cost)
R1 R2 R3
𝑻𝟏, = 22rpm T1R1 T1R2 T1R3 LS= Lifespan of the machine (5 years)
𝑻𝟐, = 32rpm T2R1 T2R2 T2R3
𝑻𝟑, = 42rpm T3R1 TTR2 S3R3 Benefit-Cost Ratio
𝑁𝐼
Time= 40 minutes 𝐵𝐶𝑅 = 1 +
𝑇𝑂𝐶

Where:
BCR= Benefit-Cost Ratio
NI= the net income derived from the equipment
TOC= total operating time
To determine the net profit, the difference of the gross
benefit and the total cost is computed as follows:
Net Profit = Gross Benefit – Total Cost
3.1 Construction of Coffee Bean Roaster
The whole structure of the coffee bean roaster was
shown in the figure below. This type of coffee bean roaster
was made of materials that are readily available in the
market. It was powered by ¼ hp electric motor and can
operate 8 hours a day, and can be cleaned easily. Pre-testing
of the roaster was done in order to find out that the machine
parts are functional so the necessary redesign was made for
the improvement of the device.
HOPPER/ PILLOW BLOCK
EXHAUST
ROASTING
CHAMBER REDUCER
OUTLET
ELECTRIC
MOTOR
RICE HULL
STOVE
BELT
FRAME
Figure 4. Machine parts.
The Actual Roasting Operation
The coffee beans used in the operation were
bought at the Tagum City Public Market and its weight
(kg) was determined by using a weighing scale. The
operating time was 40 minutes for every replication and was
measured using a stopwatch.
The actual roasting operation during the
collection of data is shown in figure 8. There were three
treatments and every treatment has three replications to
minimize error. There was 9 kg of coffee beans used for the
actual roasting operation using a coffee bean roaster in
different levels of rpm used and 1 kg of coffee beans in every
operation. Different levels of rpm were determined by the
use of a tachometer.
Figure 5. The Actual Roasting Operation
The length of time required to recover the cost of an
investment. The payback period of a given investment of the
project is an important determinant of whether to
undertake the position project, as longer payback periods as
typically not desirable for investment positions.
Calculated:
Payback period = Cost of Project / Annual Cash Inflows
Rate of Return = Annual Net Profit / Capital Investment
3.2 Roasting Efficiency
Dried coffee beans loaded in the roaster recorded
an initial weight of 1 kg. Reduction of weight is mainly
caused by the loss of moisture during roasting. The lighter
the weight of the roasted coffee after the process the more
moisture was extracted. As the amount of moisture removed
was increased, the roasting efficiency of the roaster likewise
increased.
Table 3 shows the roasting efficiency of the coffee
beans using the designed roasting machine. Roasting
efficiency was found out to be at 61.97% for 𝑻𝟏, 70.73% for
𝑻𝟐 and 82.70% for 𝑻𝟑. Treatment 1 indicates the most
favored roasting efficiency due to the fact that it recorded
the lightest weight among the three treatments.
Table 3. Roasting efficiency tested in three levels of rpm
Statistical Interpretation of Data
The interpretation of the results using the
statistical tool used in this study is one factor Tukey's Test
by the aid of ASSISTAT and these tests were based on the
calculated p-value of the data, with a 1% significance level
(𝛼 = 0.01). If the p-value is equal to or smaller than the
significance level, there is a significant difference between
the results obtained. Moreover, if the p-value is less than .01,
this means they are highly significant. On the other hand, if
the p-value is higher than the significance level, there is no
significant difference between the two or more obtained
results.
Tukey’s Standardize Range Test for Roasting Efficiency
Treatment averages
1 61.96667 b
2 70.73333 b
3 82.70000 a
The Appendix Table 1A shows the overall data
collected through the experiment. Using the ASSISTAT.
The ASSISTAT reveals as shown in the Appendix table 2A
that the treatment three (3) having 42rpm yields a
significant mean value of 82.70000. Treatments one (1) the
22rpm (2) the 32rpm, both yields insignificant effect when
compared to treatment three (3); with a mean value of
treatment one (1) 61.96667 and treatment two (2) 70.7333.
The treatment three (3) had obtained higher
results compared to treatment one (1) and two (2) due to its
high rpm because as RPM increases, beans fall off flights at
higher angles of rotation (Illy, A. and Viani, R. (1995)).
Which means also that the moisture removed to the coffee
beans during the process is not enormous, the beans were
not roasted well because the roasting speed, 42rpm was
higher than computed rpm which was 41rpm using the
formula and since the roasting efficiency was computed
based on the total weight of roasted beans divided by the
total weight of coffee beans before loading multiplied by
100, the attained result was high. While the treatment one
(1) and two (2) resulted to be insignificant because their
weight after the roasting process was lighter. The moisture
removed was higher which resulted in weight loss after
roasting and lower computed roasting efficiency.
The result was upturned because the lighter
(weight) the product after the roasting process, the more
roasted it is and more efficient. Which means that the
significant result was treatments one (1) and treatment two
(2) both having lower mean values compared to treatment
three (3) which yields the maximum.
3.3 Evaluation of Color/Appearance, Aroma, Taste
of the Ground Coffee Beans
The color, aroma, and taste are the main
requirements for determining the quality of the roasted
coffee beans. One missed requirement can affect the quality
and price of the product. The output product was tested and
tasted by the experts who have knowledge and experience
about the coffee products at the University of Southeastern
Philippines. The researcher used Likert's scale by the use of
the questionnaire to test the actual result of the said quality.
Appendix Table 3A was the result of the gathered data
during the liquid testing (Taste test) and 3B was the result
of the dry test (Raw coffee powder) using the questionnaire
with a corresponding descriptive interpretation based on
their mean scores.
Effect of roasting into the coffee based on the mean score
average of the treatments.
Treatment No. Average Descriptive
Score Interpretation
T1 3.5 This means that the
quality of roasted
sample is high.
T2 3.05 This means that the
quality of roasted
sample is moderate.
T3 2.6 This means that the
quality of roasted
sample is low.
The rating was the aroma, color/appearance, and
taste. Each roasted coffee was tasted and tested. In
Appendix Table 5A Effect of roasting into the coffee based
on the mean score showed that the highest satisfaction rate
of roasted coffee was treatment one (1) having a score
approximately 3.5 which denotes “the quality of roasted
sample is high” that the product is great and it passed the
panel of experts who conducted the test. Treatment two (2)
has a mean score of 3.05 which denotes “the quality of the
roasted sample is moderate" or acceptable and good enough
but not as good as the treatment one (1) though their mean
scores are not that of great difference. Treatment three (3)
have an approximately 2.6 result which denotes “that the
quality of the roasted sample is low”. This explains that the
quality of the roasted coffee is poor.
Treatments 1’s highest mean score could be
justified by the result of the computation using the formula
for the drum speed. Horizontal-drum roasters have to rotate
with an RPM smaller than (30/π) (g/r), where g is the
gravitational acceleration and r is the drum radius (Illy, A.
and Viani, R. (1995)).
Even though Treatment two (2) the 32rpm had a
high result like the treatment one (1) the 22rpm, it is still
higher in rpm and it is closest to the computed rpm which
was 41rpm using the drum speed formula.
3.4 Cost Estimate of a Coffee Bean Roaster
Cost estimate of the machine was computed using
different parameters which were investment cost, fixed
cost, the variable cost, and gross income. Fixed cost
parameters include depreciation, interest on capital, taxes,
and insurance while variable cost parameters include:
operation, repair and maintenance, lubrication and power
consumption (Barger, 1978).
Variable cost fluctuates directly with changes in
output. The assumption rate for an annual basis is 25
percent interest and capital, 10 percent repair, and
maintenance, 6 percent for taxes and insurance of the
investment (Viernes, 2005). The energy consumption was
included in the variable cost since the coffee roaster machine
used rice hull stove.
Cost and Return Estimate of Coffee bean roaster
Item Value
Investment Cost 15,980.00
Fixed Cost
Depreciation (5 years) 2876.4
Investment on Capital (25%) 3995
Tax and Insurance (6%) 958.8
Repair and Maintenance (10%) 1,598.0
TOTAL FIXED COST 9428.2
Variable Cost
Wages 56,700
Energy consumption&Fuel Cost (rice hull)
(Php 2394
9.00/kwhx0.1kwh/kgx1.5kg/hrx8hr/dayx18
0days/yr)
TOTAL VARIABLE COST 59,094
TOTAL OPERATING COST 84,502.2
GROSS BENEFIT 118,800
NET INCOME 34,297.8
Marginal Benefit-cost Ratio 1.40
 A.) Depreciation Cost [3] COSTER, R. 1989. Coffee the Plant and the Product
D= (IC – SV) / pp. 175-195
LS
[4] DELA CRUZ, R. 2007. bar.gov.ph, April-June 2007
= (15980 – 1598) / 5 Volume 9 Issue No. 2
= Php2876.40
[5] DE WIT, J. 2005. Coffee Roasting Process pp. 5-7
IC= Investment Cost
SV= Salvage Value [6] DEROVIRA, D. 2006. The Flavor of Roasted
LS= Life Span Coffee pp.1
B.) Net Income
Energy consumption [7] DEPARTMENT OF TRADE AND INDUSTRY
Total Roasting Capacity= 1000g/40min (DTI). 2018. DTI SEES BRIGHT PROSPECTS
= 1.5 kg/hr. AHEAD FOR PHILIPPINE COFFEE INDUSTRY.
Operation= 8hr/day @ 180 days/year
Retrieved July 22, 2019, from the World Wide
Rent of Machine= Php55.00 per kg of roasted
Web: (https://www.dti.gov.ph/27-main-
coffee bean
Gross Benefit= (Php55/kg.1.5kg/hr.) x (8hr/day x content/emb-news/11964-dti-sees-bright-
180 days/year) prospects-ahead-for-philippine-coffee-industry).
= Php 118,800.00
[8] FRENCH, O.C. 1977. Encyclopedia of Food,
Net Income= 118,800 – 84,502.2
Agriculture, and Nutrition. USA: Mc Grow Hill Inc.
= Php34,297.8
C.) Marginal Benefit-Cost Ratio
[9] GILST, V. 1976. Farm Mechanization in Developing
BCR=Gross Benefit/Total Operating Cost
Countries, AMA, Spring 6(1) pp. 82-89
= 118,800/84,502.2
= 1.40
[10] INTERNATIONALSTANDARD ORGANIZATION
4 CONCLUSION
(ISO). 2019. Coffee Market Report Sustained
Of all the treatments, the treatments one (1) with
Growth in June Global Coffee Prices. Retrieved
22rpm and two (2) with32 rpm had a mean score of 3.5 and
June 6, 2019, from the World Wide Web:
3.05, respectively. That means that the quality of the coffee
(https://www.icco.org/about-cocoa/fine-or-
sample given is high, it showed the highest efficiency level
flavour-cocoa.html).
in dry testing (powdered coffee) and liquid test (taste test)
that were carefully evaluated by the respondents to ensure
[11] ILLY, A. and R. VIANI. (eds). 1995. Espresso
the viability of the results. Treatment three (3) with 42rpm
had a mean score of 2.6. This means that the quality of the Coffee. Academic Press, London, p. 96
roasted sample is low.
[12] ILLY, E. 2002 The Complexity of Coffee pp. 86-91
Based on the result, we could identify the best
RPM suitable in roasting Coffea sp in the designed machine.
[13] KELLY, E., and R. H. FOSTER. 1983. Processing
Treatment 3 with 42 rpm, yielded the highest efficiency as
and Storage of Foodgrains by Rural Families,
shown in Table 2A. Tukey's Standardized Range Test for
Food and Agriculture Organization of the
Roasting Efficiency compared to treatments 1 and 2 with 22 United Nations Rome p. 45
rpm and 32 rpm respectively.
However, as we identified the effects of the [14] PASHLEY, T. 2017. Roaster Guide, Perfect Daily
treatment to its color, aroma, and taste, by using the
Grind
questionnaire it was determined that treatment 1 having 22
rpm obtained the highest result having a mean score of 3.5
[15] PIZON, M.P. 2003. Evaluation on the Hulling
compared to treatment 2 having a mean score of 3.05, and
Performance of Coffee Huller an Unpublished
treatment 3 having a mean score of 2.6.
Undergraduate Thesis USeP- Tagum City p. 7
Having all of this, as a result, we can conclude that
treatment one (1) having 22 rpm has the best effect in Coffea [16] PHILIPPINE STATISTICS AUTHORITY (PSA).
sp. when roasted using the designed coffee roaster machine. 2019. Major Non-Food and Industrial Crops
Quarterly Bulletin, January-March 2019.
5 REFERENCES Retrieved July 22, 2019, from the World Wide
[1] BONDAD, ND. Et al. 1984. Capsule information Web: (https://psa.gov.ph/).
Coffee Philippines Science Compton’s
Encyclopedia 1986. Vol. 4 pp. 187-191. [17] TANGIDAY, W.H. 2008. Innovative Design of a
Modified Portable Coffee Huller an Unpublished
[2] BOLAY, K., HUBBARD, K., LOOKE, B., Undergraduate Thesis USeP- Tagum City p. 1-8
MARSHALL, M., MOYER, N., (2010). Roasting
Innovation. Design of a 300 Kilogram Coffee
Roaster pp.10-12